Sheet 1 of 13

Job No. : SC-2252

Hydraulic Basis Dual Feed Ethylene Cracker
Project(ONGC)

Hydraulic Basis

Project Name : Dual Feed Ethylene Cracker Project(ONGC)

Client : OPaL

Dahej, Gujarat, India

Job No : SC-2252

0 Mar.5 '09 Preliminary KHG SMJ ICP

REV. DATE DESCRIPTION MADE BY CHK'D BY APP'D BY
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Ⅰ. General
The Hydraulic Calculation Basis is intended to describe a criteria to determine a pipe size and differential pressure of
pump, compressor and control valve and flow regime analysis of two phase flow for Dual Feed Ethylene Cracker
& Associated Units Project in Dahej, Gujarat, India.
Hydraulic calculation is to select the optimum line size within the available pressure drop.
This document will be developed throughout the detail engineering phase of the project if necessary.

1. Contents of the internal documentation after calculation

1) Documentation Summary (or similar),
2) Calculations sketch with Pressure Drop Summary Sheet (last valid revision) and
Pressure drop calculations (last valid revisions),
3) Estimated isometrics (last revision),
4) Supporting data, written communications, and
5) Old revisions of all documents, calculations, etc.

2. Initial Line size for hydraulic calculation

Line size and suction vessel elevation in proposal P&ID will be used for HYTOS initial input.

3. Required material for calculation

1) Preliminary calculation
Material balance with fluid dynamic properties for several operation cases
VDB stream data sheet
Utility balance
P&ID
Plot plan
Process data sheet
B/L condition list
Piping Material Specification
2) Isometric drawing
3) Process Flow Diagram

4. Calculation Tool
HYTOS to be used for calculation of pump loop and control valve loop.
In house line sizing program to be used for Simple single phase line sizing (utility service)

5. Consideration
1. Compressor loop, cracked gas loop and pump suction lines to be calculated using isometric drawing.
Linde K value (resistance coefficient) in Attachment #3 can be considered for optimizing the line size with the approval
of manager.
2.If VDB stream datasheet is available as MS Access or Excel format, using simple data extraction program, make easy
input the process data into HYTOS.
3. If the process data is not available until calculation, use the reference data from experienced project(ex. TASNEE)
4. The hydraulic result shall be always checked with that of reference project experienced(ex. TASNEE) before
confirm or report to manager, especially the comment's from Linde shall be checked.
5. During initial hydraulic calculation or line sizing, if the calculation result is in the marginal area against criteria,
take conservative position. ( ex. calc result velocity 2m/s - 2", criteria : 2.1m/s -> take 3" for design)
6. After initial calculation finishes, the process datasheet for r otating will be prepared and it will be revised according to
calculation result with newly available information.
7. KEEP hydraulic calculation status summary list.
8. If required, the result to be checked based on the criteria of licensor(Linde).
9. design margin : Linde's M/B case vs. owner's design margin -> to be discussed and decided

6. Complete process datasheet based on calculation result

1. Basically for Pump datasheet, Input the calculation result of one max case without margin, but round off at one decimal.
2. Basically for c/v datasheet, Input the calculation result of max/nor/min without margin, but round off at one decimal.

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Ⅱ. Criteria for Hydraulic Calculation

1. Basis of Flow Rate

It is under confirmation with Owner and final basis to be informed later.
▶ Pump Hydraulics calculation for Pump spec. preparation and suction/discharge line sizing
The one maximum case will be calculated for Pump spec. preparation.
1) Suction line(for NPSHa and line sizing)
Rated flow of operating + minimum flow of a spare pump(if vendor data not available, 25% of rated flow to be considered)
( Suggested by Proposal tech. document sec 3.13.2.15)
* ITB 2830-8110-PD-0003 sec.10
- End of curve flow for calculation of NPSH.
- Allow for spare pump start up where applicable
- 110% margin for sizing of suction line
2) Discharge line
An additional margin is not considered to the flow rate for maximum case shown on the stream data.
Column reflux line shall be sized with the maximum flow rate plus 20% margin, which is indicated on pump data sheet.
▶ Flowrate engineering margin for line sizing ( ITB 2830-8110-PD-0003 sec.10)
Refrigeration circuit : 102% of heat and mass balance to allow for efficiency deviation
Cooling water, heating
media and fuel gas lines : 110% margin on heat and mass balance
Gravity flow lines : 110% margin on heat and mass balance
Other lines : Nor margin. Use next commercially available line size

2. Equation of Frictional Pressure Drop Calculation

▶ Liquid line size is designed with Darcy's equation
4f*L mℓ 2 * Friction factor
ΔPfL =
D 2ρℓ If Re＜ 2000, f = 16 / Re
where, f : friction factor If Re ＞ 4000, calculated with Chen's equation
L : line length, m
D : inside diameter, m
mℓ : liquid flux, kg/m2s
ρℓ : liquid density, kg/m3
ε : roughness factor, m
▶ Vapor Line size is designed with compressible isothermal flow equation
2 2
M G ρa G fΔL
(Pa2-Pb2) - ln =
2RT gc ρb 2gcrH
where, f : friction factor
G : mass velocity
gc : Newton's-law proportionality factor
L : length
M : molecular weight
rH : hydraulic radius of conduit
R : gas constant
▶ For two-phase flow, the line size will be designed with a program developed by SECL which show the similar output
calculated by PIPE-3 of HTFS in pressure drop, velocity and flow regime analysis.
- Two phase velocity should be below than erosion velocity.
- The following flow patterns should be avoided as shown below.
→ Slug and plug flows (intermittent flows) for horizontal piping
→ Churn and plug flows (bubbly slug) for vertical upwards flow
→ Oscillary flow for vertical downwards flow

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3. Velocity/pressure drop per 100m Criteria for Line Sizing

.
Basically, follow the criteria of ONGC( Refer to attachment 1 and 2), however the licensor's( Refer to attachment 5)
will be used as supplement for special case.

In order to ensure the carry over of the coke particles, the decoking line should be sized so that the decoking gas
reaches a velocity as close as possible to 70 m/sec during the decoking step under which the maximum volume flow is
present (maximal velocity= 75 m/sec for discontinuous flow). Detailed instruction to be provided by Linde.

4. Inside Diameter of Pipe

According to the Project Piping Material Specification

5. Roughness
0.00015 m for carbon steel and 0 m for stainless steel
Cracked gas line, where a roughness of 1.0 mm should be considered

6. Equivalent Length
▶ In general, the equivalent length is estimated by multiply a factor to the straight length, including vertical or
horizontal line from plot plan considering fittings and valves in lines for preliminary hydraulic calculation for
initial calculation because ISO drawings for hydraulics are not available.
- For Lines in process unit, equivalent length = straight length x 3
- For interconnecting lines on the pipe rack, equivalent length = straight length x 1.5
▶ For the critical lines such as compressor loop, big line size, pump suction and low pressure system, preliminary
isometric drawing should be used for equivalent length estimation.
▶ For final hydraulic calculation, the equivalent length is calculated with straight length plus equivalent length corresponding
to pipe fittings and valves based on the ISO drawing for hydraulics when it is available.

7. Pressure Drop of Equipment and In-line Element

Equipment In-line Instrument
Heat exchanger allowable ΔP on data sheet Orifice 0.14
Filter (Cartridge) ΔP on data sheet. If not available, 0.7 bar Venturi (liquid) 0.1
Line Mixer ΔP on data sheet. If not available, 0.5 bar Venturi (vapor) 0.03
Others Positive displacement 0.7
Strainer 0.04 bar for Y, T type Turbine, Magnetic, Mass 0.5
0.1 bar for bucket type Vortex 0.3
Filter at inlet of brazed Al H/Ex 0.01 bar @ max. flow Rotameter 0.2
Metering station 0.5 bar (not applicable for this project) Target meter 1.0

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8. Determination of Control Valve ΔP

There are two cases, control valve included in pump loop and control valve which is not included in pump loop.
1) Control valve included in pump loop :
Besides the calculation for pump spec. preparation, another two cases, normal and minimum of M/B, should be done
with fixed pump head of pump spec. in order to determine a control valve's ΔP for Max, Nor and Min.
At each case, the pressure drop through in-line equipment/instrument will be reduced according to flow rate's square ratio.
Control valve ΔP shall be determined as greater figure of the followings, for each calculation(2830-8110-PD-0002, sec 4.10).
- Minimum 0.7 bar (for vapor, 0.1)
- 8 % of pump discharge (or 10% of discharge vessel pressure)
- [(1.1135 x (max. flow/nor. flow))2 - 1] x Δpfriction
- 33% of Δpfriction ( or 25% total friction drop)
2) Control valve not-included in pump loop :
Three calculations will be done in order to determine a control valve ΔP, following cases are considered.
case Case 1 Case 2 Case 3
Max (M/B) Nor (M/B) Min (M/B)
Equipment press. at starting point Min Nor Max
Equipment press. at destination point Max Nor Min
Control valve flowrate Min Nor Max
For maximum, normal and minimum case, the flow rate, pressure and physical properties are given consistently
by the stream data in different cases.
At each case, the pressure drop through in-line equipment/instrument will be reduced according to flow rate's square ratio.

Control valves should be designed to be approximately 70% open at normal flow rates. Maximum opening under all
operating cases shall not exceed 90%.

9. Pump Shutoff Pressure (2830-8110-PD-0002, sec 4.11.2.7)

For centrifugal pumps for a single consistent case,
Maximum Design Pressure = Maximum Differential Pressure + Maximum Suction Pressure
Where:
Maximum Suction Pressure = Suction Vessel Design Press.(or, Relief Valve set Press.) + Vessel Suction Head @ HLL
Maximum Differential Pressure = F x Net Differential Pressure(@ Rated capacity)
Where F is:- • 1.25 for motor driven pumps / • 1.38 for turbine driven or variable speed pumps
Note: Calculation is based on maximum operating S.G. / Level information can be referred to Datasheet.

For reciprocating pumps, these should be provided with discharge relief valves, the pressure of which should
be set to avoid the pump over-pressurizing any system into which it discharges.

10. Pump NPSH, Low Liquid Level in Suction Vessel & Pump centerline (2830-8110-PD-0002, sec 4.8.1.3)
In order to avoid the possibility of cavitation and vibration in centrifugal pump, the size of pump suction pipe and elevation
of suction vessel shall be decided considering NPSHa is greater than NPSHr by pump manufacturer plus a safety factor
as below.
NPSHa ≥ NPSHr + 1.0 m (safety factor)
up to design capa. for boiling, dissolved gases, foaming another liquids
NPSHa ≥ NPSHr + 2.0 m (safety factor)
up to design capa. for BFW pumps of initial stage, it can be reduced with vendor data and ISO dwg.
Liquid level in suction vessel and pump centerline shall be considered as follows, refer to datasheet for level inform. ;
- Tangent line in vertical vessel
- Bottom line in horizontal vessel
- LLL in Tanks
- Pump impeller center line for horizontal pump
- Pump suction nozzle center line for vertical pump
The following elevation for pump center line shall be assumed untill vendor information is available
M3/h Centerline elevation
up to 45 0.76 m
45 -225 0.91 m
225-2270 1.07 m (+ 0.3 m)
2270-4540 1.37 m (+ 0.3 m)
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Attachment #1
Recommended High limit for Line Sizing (2830-8110-PD-0002, sec 4.9.1)

1. Liquid Flow
The guidelines cover most normal situations for systems within unit battery limits, but they may not be applicable for all
cases. For critical services and long headers, the total pressure drop in the system must be checked to ensure the
system meets the design pressure balance, whether or not individual process lines meet the pressure drop and velocity
criteria given here. This standard may not apply to critical services, such as slurry lines or high pressure piping, for which
reference should be made to additional standards.

1) Pump Suction Lines (1)

DelP/100m bar
Item Velocity m/s Remark
(approx.)

Pipe Dia. -8" and less

Bubble point Fluids 0.113 0.91
Sub-cooled Fulids 0.453 2.44
Pipe Dia. Greater than 8"
Bubble point Fluids 0.113 1.83
Sub-cooled Fulids 0.453 3.66
Note 1. Pump suct. line dia. should normally not be more than two (2) standard line sizes larger than the pump suction

2) Pump Discharge Lines (Line sizing is a trade-off between piping installation costs and operating costs.)
Materal Type
Flow rate Carbon Steel Alloy
(bar/100m) (bar/100m)

0 - 60 m3/h 0.6 - 2 1.4 - 3.5

60 - 160 m3/h 0.3 - 1.6 0.9 - 2.5

+ 160 m3/h 0.2 - 0.9 0.5 - 1.6

3) Other liquid lines

DelP/100m bar
Item Velocity m/s Remark
(approx.)

Liquid Transfer Line 0.339 3.66

Cooling Water Line 0.339 3.66
Steam Condensate Lines (1) - 0.61
Line size to be confirmed by
Reboiler Trap-out lines (2) 0.068 1.52
Mech. (thermal rating)
Line size to be confirmed by
Reboiler Return lines 0.068 -
Mech.(thermal rating)
Note 1. Or as required by system pressure balance.
Note 2. Standard tower draw-off rates should be referred to (see Section 5.1.2).

For liquid lines with orifice plates, if the liquid velocity is too high, swaged-up meter runs may be required. Velocities for lines
containing orifice plates shall be limited to:
2” and over < 3.4 m/s
Except 14” and over Sch. 80 < 3.1 m/s
In cases where higher velocities are essential the Instrument Group should be consulted.

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Attachment #2
Recommended High limit for Line Sizing (2830-8110-PD-0002, sec 4.9.1)

2. Vapor
The guidelines cover most normal situations for systems within unit battery limits, but they may not be applicable for all
cases. For critical services and long headers, the total pressure drop in the system must be checked to ensure the system
meets the design pressure balance, whether or not individual process lines meet the pressure drop and velocity criteria
given here. For long vapour lines, such as flare headers or vacuum transfer lines, when the ΔP > 10% P, a compressible
flow calculation procedure should be adopted.

1) Hydrocarbon Lines
DelP/100m bar
Item Velocity m/s Remark
(approx.)

0.07 bara or less 0.01 122/√ρ (2)

0.5 bara or less 0.03

0.5 to 3.5 barg 0.11

3.5 to 10 barg 0.34

10 to 35 barg 0.68

Over 35 barg 1.13 (1)

Note 1. 0.5 % of pressure level
Note 2 ρ = gas density, kg/m3

2) Steam Lines ( < 100 m length )

DelP/100m bar
Item Velocity m/s Remark
(approx.)

0.07 bara or less 0.01

0.5 bara or less 0.05

0.5 to 3.5 barg 0.11

3.5 to 10 barg 0.34

10 to 35 barg 0.68

Over 35 barg 1.13 (1)

Note 1. 0.5 % of pressure level

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Attachment #3

Linde K value

In this attachment Resistance Coefficients which can be employed for a preliminary sizing of the lines are supplied.
The actual coefficients for the different pipe fittings, valves, filters, etc, should be determined by SECL according to the piping
components (type, quality, etc) to be used for this specific job (once the manufacturers information is available), and to the
Piping Specifications.
When a decision is met concerning the suppliers of piping material for the various pipe classes, it is advisable to develop a
summary of Resistance Coefficients to be used for the pressure drop calculations. This summary can have the form as
supplied in this attachment, and its level of detail / accuracy should be determined according to the following criteria:
- Expected savings by the use of a more accurate coefficient,
- Cost (time required) of determining an accurate coefficient,
- Pipe class and line size,
- Purpose of the calculation (e.g. normally the "real" or greater coefficient is to be used for line sizing, but the "real" or smaller
coefficient should be used when searching for the maximum possible flow through a line for example),
- Number and type of piping components in the line, and the proportion of pressure loss originated by them in relation to the
total pressure loss,
- Total pressure loss available, and
- Accuracy of the pipe routing considered for the calculation.

a) Resistance coefficients for 90 deg smooth bends:

Pipe size

D ≤ 3" 3" < D ≤ D > 16"

16"
0.15 mm 0.4 0.3 0.25
Roughnes 0.1 mm 0.38 0.29 0.25
s
1 mm 0.8 0.5 0.33

Remarks: The above figures are based on the following:

- Reynolds number greater than 100000 (for lower Reynolds numbers the K value increases rapidly).
- Relation r/D = 1.5

b) Resistance coefficients for 45 deg smooth bends:

The Resistance Coefficients are about 65 % of the coefficients for 90 deg smooth bends.

c) General Resistance Coefficients:

Piping component Resistance Coefficient

90 deg segmental bend 0.35

Pipe entrance 1.5
Pipe exit 1
Y-strainer / T-strainer 7
Pot-type strainer 4
Gate valve 0.2
Butterfly valve ND 2" to 8" 0.76
ND 8" to 14" 0.49
ND 16" to 24" 0.33
Ball valve 0.1
Control valve 6
Disk check valve 5
Check valves 7

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d) Expansion pieces:
Note: in the following Resistance Coefficients only the friction portion is considered.

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e) Reduction pieces:
Note: in the following Resistance Coefficients the friction loss and the loss due to the pressure head variations
are considered. The coefficient K1 is referred to D1.

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f) T-pieces:
The Resistance Coefficients are expressed as a function of the relation of flows Ga / Gz. (same line sizes at z, d & a)

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Attachment #4

Recommendation for Line Sizing (2830-8110-PD-0002, sec 4.9.2.2)

Tower Draw-Off Line Sizing

Liquid from a tower tray is aerated to some extent depending on the foaminess of the gas-liquid mixture. The recommended method
for sizing draw offs employs the following criteria:

-The depth of the draw-off pan to be 1 – 1½ times the nozzle diameter. The minimum allowable depth is 200mm.
- Allowable velocity may vary from 0.7 m/s to 1.2 m/s depending on the nozzle size
(See Attachment 1 –Capacities of Side- an Draw-off Nozzles).
- The nozzle is to be swaged down to a line size which will not exceed 0.1 bar/100m pressure drop. The swage is to occur at a
point in elevation 1.2m below the nozzle draw-off. Only lines 0.2m and larger are to be swaged down, small lines will be
maintained at nozzle size to the pump or first exchanger
(See Attachment 2 - ‘Typical Swaged Lines After Side-pan Draw-off Nozzle’).

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Attachment #5

Velocity Criteria for Line Sizing (By Linde)

Liquid Suction Side, m/s Discharge Side. m/s Remark

General 0.5 ~ 1.0 1.0 ~ 3.0
Naphtha 1.5 2.0
Boiler Feed Water 0.5 ~ 1.0 1.0 ~ 3.0
Steam Condensate 0.5 ~ 0.8 1.5 ~ 3.0
Process Water 0.5 ~ 0.8 1.5 ~ 3.0
Cooling Water 0.7 ~ 1.5 2.5 upto ND 300
3.0 from ND 400
Caustic (NaOH) 0.8 ~ 1.2 1.0 ~ 2.0
Methanol 0.5 ~ 0.8 1.0 ~ 1.5
Corrosion Inhibitor 0.5 ~ 0.8 1.0 ~ 1.5
Polymerization Inhibitor 0.5 ~ 0.8 1.0 ~ 1.5
Fuel Oil 0.7 ~ 1.0 1.5 ~ 2.0
Luburication Oil 0.5 ~ 0.8 1.0 ~ 1.5
Quenching Oil 0.5 ~ 0.8 1.0 ~ 1.8
Gasoline 0.7 ~ 1.0 1.0 ~ 1.8
Liquid C2, C3 & C4 0.7 ~ 1.0 1.0 ~ 2.0 * * : below 1 m/s when at boiling point
Slope piping to pits 0.3 upto ND 80
0.4 from ND 100 upto 200
0.7 upwards ND 250
Lined Pipes (Rubber-, Cement-, Asphalt-) upto 1.8

Steam Velocity, m/s Remark

VHP steam 20 ~ 40
HP steam 20 ~ 50
MP steam 20 ~ 40 upto ND 300
40 ~ 50 from ND 300
LP steam 15 ~ 25

Gas Velocity, m/s Remark

Nitrogen 15 ~ 25
Fuel Gas 5 ~ 25
Sour Gas 5 ~ 25
H2 rich Gas below 50
Instrument Air 15 ~ 25
Plant Air 15 ~ 25
Max. velocity at inlet of Silencer 0.6 Mach
Decoking Gas 30 ~ 65

Gas in general, according to process pressure Velocity, m/s Remark

upto 3 14 ~ 40
3~7 12 ~ 35
7 ~ 15 10 ~ 30
15 ~ 28 8 ~ 18
28 ~ 34 4 ~ 10

Special Cases
Nitrogen as purge gas in the Flare System: min. velocity=0.03m/sec
Inlet of process steam traps: max. velocity = 0.5 m/sec

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